Packaging system

ABSTRACT

A packaging system ( 4 ) comprising a plurality of first cartons ( 1 ) each forming a first package comprising a group of articles (A) and a second carton ( 2 ) for packaging a group of said first packages ( 1 ) whereby forming a secondary package. The second carton comprises ( 2 ) a plurality of removable portions ( 132   a,    132   b,    132   c,    132   d ) each forming a part of a respective one of the first packages ( 1 ). Each of the first cartons ( 1 ) being disposed around a respective group of articles (A) and secured to a respective one of the removable portions ( 132   a,    132   b,    132   c,    132   d ) of the second carton ( 2 ) through at least one engaging aperture ( 146   a ) defined in the second carton ( 2 ) and wherein a respective removable portion of the second carton ( 2 ) is coupled to the remainder of the second carton ( 2 ) by a frangible connection ( 170 ) such that each of the first packages ( 1 ) is removable from the secondary package ( 2 ) by breaking the frangible connection ( 170 ).

FIELD OF INVENTION

The present invention relates to a packaging system for multiple packaging of articles and more particularly, but not exclusively, to a packaging system in which a secondary package contains at least one, say a plurality of primary packages.

BACKGROUND OF INVENTION

It is known to provide cartons for packaging multiple articles. EP 0,428,397 to Saulas and EP 0,694,011 to Blin et al disclose cartons comprising multiple compartments connected together by a common top panel. Such cartons are expensive; requiring substantial quantities of material and their complex structure leads to an increased complexity in their method of construction.

It is desirable to provide a packaging system in which articles are packaged in a primary package which may be printed with branding or advertising material to promote the goods being packaged. Furthermore, it is also desirable to provide a secondary package for transportation, protection and/or storage of the primary packages.

Of course, because of its ancillary purpose, it is desirable to minimise the costs and complexity associated with a secondary package, without reducing the aesthetic appeal of the primary package or its structural integrity. The present invention seek to overcome, or at least mitigate, the problems in the prior art.

Furthermore, the present invention seeks to provide an additional advantage by reducing the waste associated with the production of the secondary packaging.

SUMMARY OF INVENTION

Accordingly, a first aspect of the invention provides a packaging system comprising a first carton each for forming a first package comprising a group of articles and a second carton for packaging a group of said first packages whereby forming a secondary package wherein a portion of the second carton forms a part of the first package, said first carton being secured around the group of articles to the second carton and wherein said portion of the second carton is coupled to the remainder of the second carton by a frangible connection such that the first package is removable from the secondary package by breaking the frangible connection.

Preferably, the first carton comprises a first panel hinged on opposed sides to a second and third panel respectively wherein each of the second and third panels is hinged to a securing panel said securing panels being secured to a removable portion of the secondary carton.

Preferably, the first carton together with said portion of the second carton forms a tubular structure about the group of articles.

Preferably, the second carton comprises side and/or end walls wherein said side or end walls close at least one end of the tubular structure.

Preferably, the second carton comprises apertures for receiving portions of the first carton such that the first carton may be secured to the second carton.

Preferably, the second carton comprises tabs for being received by tab receiving recesses such that the packaging system may be stacked with another like packaging system whereby said packaging system and said another package system interlock with one another.

Preferably, the tab receiving recesses are formed by apertures struck from the second carton.

Preferably, the apertures for receiving portions of the first carton also form the apertures for forming the tab receiving recesses.

Accordingly, a second aspect of the invention provides a carton for packaging a group of articles having a first panel hinged on opposed sides therefore to a second and third panel respectively said second and third panels each being hinged to a securing panel respectively wherein in use the carton forms a package when secured about a group of articles to the secondary carton.

Accordingly, a third aspect of the invention provides a secondary carton for packaging a primary carton said secondary carton comprising apertures for receiving a portion of the primary carton, a detachable portion for being secured to securing panels of the primary package and frangible connections between said detachable portion and the remainder of the secondary carton.

Accordingly, a fourth aspect of the invention provides a method of assembly a packaging comprising providing a first blank for forming a primary carton and a second blank for forming a second carton, loading one of said first and second cartons with a group of articles, and securing the first carton to the second carton wherein a portion of the second carton together with the first carton and the group of articles form a package which is removable from the packaging system by breaking a frangible connection between said portion of the second carton and the remainder of the second carton.

Preferably, the first blank is conveyed over the article group and folded about the sides of the article group.

Preferably, the first blank and the article group are positioned over a second blank, portions of the first carton are received in apertures formed in the second blank and are secured to the second blank and the side and end walls of the second are folded about the article group and first carton.

Preferably, a first and second blank are secured to one another to form a tubular structure for receiving said group of articles wherein said tubular structure is loaded with an article group prior to assembly of the second blank into the second carton.

Accordingly, a fifth aspect of the invention provides a packaging apparatus comprising one or more primary cartons for packaging one or more articles therein and a secondary carton for retaining one or more of said primary cartons, wherein at least one of said primary cartons are retained within said secondary carton and wherein at least a portion of said primary carton is common to at least a part of said secondary carton.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a plan view of a blank for forming a carton according to a preferred embodiment of the present invention;

FIG. 2 is a plan view of a blank of a secondary package according to a preferred embodiment of the present invention;

FIG. 3 is a perspective view of a carton formed according to a preferred embodiment of the present invention;

FIG. 4 is a perspective view of the base of a secondary package into which the cartons of FIG. 3 have been loaded;

FIG. 5 is a perspective view of the top of the secondary package of FIG. 4 shown loaded with cartons of the type shown in FIG. 3; and

FIG. 6 shows a perspective view of the base of a secondary package according to an alternative embodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

Referring to FIG. 1 there is shown a blank 10 for forming in part a carton 1 as shown in FIG. 3.

The blank 10 comprises a series of panels 12 a, 12 b, 14, 16 a, 16 b hinged one to the next for forming a top panel 14, and opposed side panels 12 a/12 b, 16 a/16 b. Each of the opposed side panels 12 a/12 b, 16 a/16 b comprise upper side panels 12 b, 16 b and lower side panels 12 a, 16 a.

The upper side panel 12 b is hinged to the lower side panel 12 a by a fold line 11 and the upper side panel 16 b is hinged to the lower side panel 16 a by a fold line The upper side panels 12 b, 16 b, are hinged to opposing edges of the top panel 14 by fold lines 13 and 15 respectively.

Securing flaps 18 a, 18 b are hingedly connected to the distal edge of each lower side panel 12 a/16 a; flaps 18 a, 18 b are able to receive adhesive in use. The securing flaps 18 a and 18 b are shorter in length than the series of panels 12 a, 12 b 14, 16 a, 16 b and are disposed centrally along the length of lower side panels 12 a and 16 a respectively.

Lower side panels 12 a and 16 a each comprise chamfered corners 28 at a lower free edge 29 of the lower side panel 12 a, 16 a.

Top panel 14 comprises a pair of finger engagement tabs 20 formed by curved cut lines 22 a and 22 b disposed at opposite ends of a cut line 24, such that curved cut lines 22 a, 22 b and cut line 24 define in part a pair of tabs 26 a, 26 b. Each tab 26 a, 26 b of the pair of tabs 26 a, 26 b is adapted to be folded about notional lines disposed between the extremities of curved cut lines 22 a, 22 b.

Turning now to FIG. 2 there is shown a plan view of a blank 100 for forming a secondary package 2 of the type shown in FIG. 4. Blank 100 comprises a pair of opposed side wall panels 110,112 hinged by fold lines 125 and 127 respectively to a base structure for forming opposed side walls 110,112.

Optionally, side walls 110, 112 each comprise a plurality of first and second apertures 142 and 140. First apertures 142 are circular whereas second apertures 140 are rectangular. First and second apertures 142 and 140 are provided to allow ventilation of the package, and/or to provide windows for viewing parts of cartons 8, for example display or advertising panels, when cartons 8 are disposed within the secondary package 2. First and second apertures 142, 140 also serve to reduce the weight of the secondary package 2. First and second apertures 142, 140 may also be engaged by a packaging machine during assembly of the secondary package 2. Side end closure flaps 118/124 and 120/122 are coupled to side walls 110, 112 respectively along respective fold lines 121/111 and 117/115.

Base end closure flaps 114, 116 are coupled to the base structure along fold lines 119 and 113 respectively.

An elongate aperture 148 is struck from each base end closure flap 114, 116. The elongate aperture 148 is disposed centrally within each base end closure flap 114, 116. A lower portion of each elongate aperture 148 is coincident with and interrupts fold lines 119 and 113. Elongate apertures 148 form a handle structure 150.

The base structure comprises four detachable base panels 132 a, 132 b 132 c and 132 d disposed between a pair of support members 126, 128/130. Detachable base panels 132 a, 132 d are disposed between support members 130, 126 where support member 130 is disposed at one end of the base structure in hinged connection with end closure flap 116 and along fold line 113 and support member 126 is disposed centrally within base structure and in hinged connection with side walls 110, 112 along portions of fold lines 125 and 127 respectively.

Detachable base panels 132 b, 132 c are disposed between central support member 126 and support member 128. Support member 128 is disposed at an opposed end of the base structure and is in hinged connection with base end closure flap 174 along fold line 119.

Engaging aperture 144 a separates detachable base panels 132 a and 132 d and engaging aperture 144 b separates detachable base panels 132 c and 132 b. Engaging apertures 144 a is disposed between end support member 130 and central support member 126, whereas engaging aperture 144 b is disposed between end support member 128 and central support member 126.

Detachable base panels 132 a, 132 b, 132 c 132 d are maintained in connection with support members 126, 128, 130 via nick portions 170, or other frangible connection means, disposed substantially at each corner of the detachable base panels 132 a, 132 b, 132 c, 132 d.

Engaging aperture 146 a, 146 b, 146 c, 146 d separate detachable base panels 132 a, 132 b, 132 c, 132 d from their respective adjacent side wall 110, 112. In the preferred embodiment, engaging apertures 146 a, 146 b, 146 c, 146 d are struck from the respective adjacent side wall 110, 112 and form one part of a complementary interlocking mechanism for interlocking multiple secondary packages 2 when stacked one upon another. Engaging apertures each 146 a, 146 b, 146 c, 146 d, form an engaging edge 168 which engages with an edge of a second part of the complementary interlocking mechanism.

The second part of the complementary interlocking mechanism is formed by tabs 160 which are disposed on upper edges of the side walls 110, 112. When multiple secondary packages 2 are stacked one upon another the tab 160 from a lower secondary package 2 engages with the portion of engaging aperture 146 a, 146 b, 146 c, 146 d struck from the respective adjacent side wall 110, 112 of an upper secondary package 2, thereby preventing longitudinal movement of the upper secondary package 2 relative to the lower secondary package 2.

Transverse interlocking supports are provided in part by tabs 162 disposed on upper edges of side end closure flaps 118, 120, 122, 124 and in part by apertures 166 struck from lower end closure laps 114, 116 and base structure and in part rebate portions 164 when secondary packages 2 are stacked on side end closure flaps 118, 120, 122, 124. Tabs 162 engage with the recess 166 formed in base end closure flaps 114, 116.

The rebate portions 164 of side end closure flaps 118, 120, 122 124 are in registry with aperture 166 in the assembled secondary package 2 such that the side end closure flaps 118, 120, 122, 124 do not interfere with the transverse interlocking mechanism formed by apertures 166 and tabs 162.

Turning now to FIG. 3 there is shown a perspective view of the base of a carton 1 which forms a primary package for a group of articles A. It can be seen that the blank 10 of FIG. 1 has been wrapped around the top and sides of a group of articles A. One of the detachable base panels 132 a from blank 100 has been secured to the securing flaps 18 a, 18 b by means of adhesive or other mechanical fixing means known in the art.

FIG. 4 shows a perspective view of the base of the secondary package 2, it can be seen that four blanks 10 have been assembled around four distinct groups of articles A. The blanks 10 have been secured to a respective one of the detachable base panels 132 a, 132 b, 132 c, 132 d.

The packaging system 4 shown in FIG. 4 is assembled by forming groups of articles A and bringing them over a respective one of the detachable base panels 132 a, 132 b 132 c, 132 d and bringing a blank 10 over each group of articles A prior to or simultaneously with the step of bringing the group of articles A over the blank 100. The side panels 110, 112 of the blank 10 are folded about each group of articles A prior to placing groups of articles A upon the blank 100.

Securing flaps 18 a, 18 b of each of the blanks 10 are received in engaging apertures 146 a, 146 b, 146 c, 146 d and 144 a, 144 b respectively.

Securing flaps 18 a, 18 b are then secured to the detachable base panels 132 a, 132 b, 132 c, 132 d. At the same time as, or subsequently to, folding and securing the securing flaps 18 a, 18 b to the blank 100 the side walls 110, 112 are folded about all of the groups of articles A thereby formed.

The side end closure flaps 118, 120, 122 and 124 are then folded about their respective fold lines 121, 117, 115, 111 to be perpendicular with a respective sidewall 110, 112.

The base end closure flaps 114 116 are then folded about fold lines 119, 113 respectively to be disposed in face contacting relationship with respective side end closure flaps 118, 120, 122, 124. The base end closure flaps 114, 116 are secured to the side end closure flaps 118, 120, 122, 124 by means of adhesive or other mechanical locking means known in the art.

The assembly process forms a packaging system 4 having, in the preferred embodiment, a plurality of independently packaged groups of articles A, each independently packaged group of articles A shares a respective portion 132 a, 132 b, 132 c, 132 d of the base panel of the secondary package 2 (best illustrated in FIG. 5), this respective portion 132 a, 132 b, 132 c, 132 d of the base panel of the secondary package 2 forms a detachable base panel 132 a, 132 b, 132 c, 132 d of carton 1 as is best illustrated in FIG. 3. When a group of articles A is removed from the secondary package 2 the respective portion 132 a, 132 b, 132 c, 132 d of the base panel of the secondary package 2 is separated from the remainder of secondary package 2 as illustrated in FIG. 3. This is achieved by breaking the frangible connection 170 between one of the respective portion 132 a, 132 b, 132 c, 132 d and the respective support members 126, 128/130.

Each separate independently packaged group of articles A comprises a carton 1 and twelve articles A arranged in a double tier stack of a two by three array of articles A. In the assembled packaging system 4, the chamfered corners 28 provide an edge 29 which prevent the primary package or carton 1 falling from the secondary package 2 should the frangible connections 170 coupling a detachable base panel 132 a, 132 b, 132 c, 132 d break undesirably during transit.

The chamfered corners 28 also allow the blank 10 to be easily manipulated during assembly such that securing panels 18 a, 18 b can protrude sufficiently through engaging apertures 146 a, 146 b, 146 c, 146 d, whilst being secured to the respective detachable base panel 132 a, 132 b, 132 c, 132 d.

It will be understood by those skilled in the art that the chamfered corners 28 are optional and that square corners may be provided which would alternatively prevent the primary package falling from the secondary package 2. It will be apparent to those skilled in the art that apertures 140 and 142 are entirely optional.

FIG. 6 illustrates an alternative embodiment of the present invention in which like features have been assigned the same reference numerals as the previous embodiment but with the prefix “3” appended. It can be seen that the support panels 326, 328 and 330 have been manufactured to have straight edges rather than the wave like shaped nature of panels 126, 128, 130 shown in the embodiment of FIG. 4.

The support panels 126, 128, 130 of the embodiment shown in FIG. 4 have recessed edges located to be substantially in registry with the corners of the base panel 132 a, 132 b, 132 c, 132 d of the primary carton 1, which primary carton 1 comprises detachable panel 132 a, 132 b, 132 c, 132 d and which detachable panels are substantially “I” shaped.

It will be appreciated by those skilled in the art that detachable panels (not shown) for use with the embodiment of FIG. 6 may be shaped so as to complement the support panels 326, 328, 330 and therefore need not take the “I” shaped form of the embodiment of FIG. 4.

Furthermore, it will be appreciated by those skilled in the art that the base panel of the embodiment shown in FIGS. 2 and 5 when viewed in the manner shown in FIG. 6 will be substantially similar to that shown in FIG. 6, except for the support panels 126, 128, 130 which will be curved or wave like in shape.

It will be appreciated by those skilled in the art that alternative configurations could be employed for example each separate group need not be limited to having a double tier or each tier to having a two by three array of articles A. In the preferred embodiment each array of articles is frangibly connected to at least one other article A in the array however this need not be so and the articles A may not be coupled to one another.

Furthermore the packaging system 4 need not result in a group of four groups of cartons in a two by two array as shown in FIG. 5 but may be any configuration desired for example a three by one array. Accordingly detachable panels 132 a will be sized, shaped and configured to accommodate the size shape and configuration of the primary carton 1. In another embodiment the cartons 1 accommodated by the secondary package 2 are sized and/or shaped differently to one another and detachable panels 132 a, 132 b, 132 c, 132 d are sized and shaped accordingly.

It will be further appreciated that one of the benefits of the present invention is that the amount of secondary packaging to be disposed of in store is reduced. Any directional references used in the above description are incorporated for clarity only and are not intended to be limiting. It will therefore be recognised that as used herein, that terms such as “top”, “base”, “side”, “end”, “inner”, “outer”, “upper”, and “lower” with respect to the panels of the relative terms , and that the carton formed from the blank may be reoriented as necessary or as desired. Any reference to a hinged or foldable connection should not be construed as necessarily referring to a single fold line only: indeed, it is envisaged that a hinged or foldable connection can be formed form one or more of the following, a score line, a frangible line or a fold line, without departing from the scope of the present invention. It is specifically contemplated that the arrangement may be incorporated into other carton types such, as, for example, fully enclosed cartons. 

1. A packaging system comprising a plurality of first cartons blanks each for forming a first package about a group of articles and a second carton blank, having removable portions, for forming a second carton for packaging one or more groups of articles, wherein each of said plurality of first carton blanks, in combination with a respective removable portion of said second carton blank form a first carton about a respective one of said one or more groups of articles, wherein the removable portions of said second carton are detachable therefrom such that each of said first cartons are individually separable from the second carton.
 2. The packaging system of claim 1, wherein each of the first cartons blanks comprises a first panel, a second panel, a third panel and a securing panel, wherein said first panel is hinged at opposing side edges to said second and third panels respectively, and wherein each of the second and third panels is hinged to a securing panel, said securing panels of said each first carton blanks being secured to a respective one of the removable portions of the second carton.
 3. The packaging system of claim 1, wherein each of the first carton blanks together with a respective one of the removable portions forms a tubular structure about each respective group of articles.
 4. The packaging system of claim 1, wherein the second carton comprises side walls wherein said side walls at least partially close at least one end of the tubular structure.
 5. The packaging system of claim 1, wherein the second carton blank comprises a main panel having a first side and a second side and pairs of apertures each of which receives a securing portion of said first carton blank wherein said securing portions are inserted through a respective aperture from said first side and secured to said second side.
 6. The packaging system of claim 5, wherein the second carton comprises tabs for being received by tab receiving recesses of the second carton such that the packaging system may be stacked with another like packaging system whereby said packaging system and said another package system interlock with one another.
 7. The packaging system according to claim 6, wherein said tab receiving recesses are formed by apertures struck from the second carton.
 8. The packaging system of claim 6 wherein the apertures for receiving portions of the first carton also form the tab receiving recesses.
 9. A carton for packaging a group of articles formed in part from a first carton blank having a first panel hinged at opposing side edges thereof to second and third panels respectively, said second and third panels each being hinged to a securing panel respectively, wherein in use, the carton forms a package when disposed about a group of articles and secured to a panel of a blank forming a second carton, wherein said second carton provides in part a fourth panel of the carton.
 10. A secondary carton for packaging primary cartons, comprising engaging apertures each for receiving a portion of a respective one of the primary cartons, a plurality of detachable portions for being secured to the primary cartons respectively and frangible connections between each of said detachable portion and the remainder of the secondary carton wherein said detachable portion forms a panel of the primary carton.
 11. A method of assembling a packaging system, comprising providing a plurality of first blanks for forming a first carton and a second blank for forming a second carton loading one of said first and second cartons with a plurality of groups of articles, and securing the first blank to the second blank about a respective one of said plurality of groups of articles, wherein portions of the second carton together with each of the first blanks and the group of articles form packages which are removable from the packaging system by breaking a frangible connection between respective ones of said portions of the second carton and the remainder of the second carton.
 12. A method according to claim 11 wherein said first blank is conveyed over the group of articles and folded about the sides of the group of articles.
 13. A method according to claim 12 wherein the first blank and the group of articles are positioned over a second blank, portions of the first carton are received in apertures formed in the second blank and are secured to the second blank and side and end walls of the second blank are folded about the group of articles and said first carton.
 14. A method according to claim 11 wherein a first and second blank are secured to one another to form a tubular structure for receiving said group of articles wherein said tubular structure is loaded with a group of articles prior to assembly of the second blank into the second carton.
 15. A packaging apparatus comprising one or more primary cartons for packaging one or more articles therein and a secondary carton for retaining one or more of said primary cartons, wherein at least one of said primary cartons are retained within said secondary carton and wherein at least a portion of said primary carton is common to at least a part of said secondary carton.
 16. The packaging system of claim 5, wherein said removable portions are defined in part by said apertures and are coupled to the remainder of the second carton by a frangible connection such that each of the first packages is removable from the second carton by breaking the frangible connection.
 17. The packaging system of claim 3, wherein said removable portion couples between the second and third panels and forms a fourth panel in combination with said securing panels to complete said tubular structure. 